Hager’s product guide to the 4th Edition Introduction

Since 2000, the 3rd Edition wiring regulations have provided the rules that must be followed to ensure that electrical installations are safe in Ireland. The ETCI have responded to CENELEC HD60384 and are implementing a new set of wiring regulations aimed at making installations even safer for installers and end users. The introduction of the 4th Edition of the Wiring Regulations on the 1st October 2009 will have a major impact on Electricians, Electrical Contractors, Architects and Consultants.

Installations designed from 1st October 2009 must comply with this new set of Regulations, several of which will have implications on circuit design.

Hager’s Product Guide to the 4th Edition is designed to highlight the impact of the new Wiring Regulations on Hager products, and provide advice on which product to choose in order to be com- pliant.

Hager is offering tailored training sessions throughout 2009 for anybody interested in finding out more about the new Regulations. Please log on to www.hager.ie or contact us for more details.

2 Objectives

One of the obvious objectives of the 4th Edition Regulations is protection against electrical accidents. Some of the terminology has been updated in Part 1 as follows:

131.2.1 – Basic Protection (protection against direct contact) 131.2.2 – Fault Protection (protection against indirect contact) – Protection against voltage disturbances (overvoltage, undervoltage, electromagnetic emissions generated within installation) 131.7 – Protection against power supply interruption

The new regulations are shaped around providing the highest level of protection in each of these situations, and throughout this booklet you will find the corresponding compliant Hager products.

Scope

In Part 1, Chapter 11 of the 4th Edition Wiring Regulations, the list 1. Marinas 6. Mobile Installations on the right of applicable installations has been extended. 2. Medical Locations 7. Wall/Ceiling Heating Contractors and planners must make sure that products being 3. Exhibitions / Fairs 8. Caravans installed in any of these installations are compliant with the 4. Photovoltaic Systems 9. Temporary Installations new regulations. 5. ELV Lighting

3 Cable Joints & Connections

Part 5, Chapter 13 of the regulations recognise that electrical joints are a potential source of overheating and if not securely made could ultimately cause a fire. For this reason there are several regulations rela- ting to electrical connections. Regulation 134.1.4 states that “connections between conductors and other electrical equipment shall be made in such a way that safe and reliable contact is ensured”.

4 Issues with traditional connections The wiring method illustrated (right) is a common cause of non-compliance particularly with lighting circuits and the connections to downlighters in particular.

It can be seen that the sheath of the flex is not enclosed. This is due to the connection method not facilitating an easy means of enclosing the outer sheath, a non-compliance with regulation 526.5.3

Another problem is that during installation and maintenance, mechanical strain may be placed on the terminations of the conductors within the junction box. This is due to a lack of a clamping method for the cable, a non compliance with regulation 522.8.5

A further potential problem can be found within the junction box (left) concerning the type of conductors that are typically terminated. It is often the case in domestic installations that solid twin & cpc cables will be used for the fixed wiring with the conductor to the light fitting (or if the lighting is ELV) being a flexible conductor.

Care must be taken to ensure the strands of the flexible cable are secured adequately in the terminal and have not been damaged to ensure compliance with regulation 526.2.1. Also, as can be seen in this illustration, when the conductor was removed for inspection it is clear that some of the strands have been damaged during termination.

As we have discussed, unless using a solution such as main- tenance free terminals, the access to electrical connections should be adequate for their safe and proper inspection, testing and maintenance. In this respect, connections should be in a location where they can reasonably be reached and where there is adequate working space.

Where connections are made in roof spaces and inter-floor- spaces the enclosures containing the connections should normally be fixed and provision must be made for their access. Providing these two constraints are complied with, then the continued use of standard circular junction boxes remains acceptable. The requirement for accessibility applies equally to the situation where, because of damage to an existing cable, a repair is effected by the introduction of a joint. The joint must be accessible; alternatively the joint may be made by an appropriate method, a maintenance free terminal for example.

5 Maintenance free connections

Regulation 526.3.4 states that: “Connections that are not accessible shall be made by special means that prevent loosening, such as brazing, welding, exothermal heating or crimping” Junction boxes are commonly used during alterations and additions to an installation. With certain exceptions regulation 526.3 requires that every connection shall be accessible for inspection, testing and maintenance. Unless provision is made for access, where boarding, carpet or other similar covering is laid over a junction box with screw terminals, it may not be considered accessible and maintenance free terminals should be used. This is made clear in Regulation 526.3.4, which states that: “Connections that are not accessible shall be made by special means that prevent loosening, such as brazing, welding, exothermal heating or crimping” Designers and installers must make the right choice when selecting junction boxes in order to comply with the new regulations. See the hager chart below, which should aid in the selection for future installations.

Description N° of Terminals Terminal Rating Reference Benefits/ Considerations Downlighter Junction Box 3 x 3 x 1,5mm2 16 A J501 Provided with cable 1 x 2 x 1,5mm2 32 A J501 clamps and separate ter- minals for flex

Maintenance Free 3 x 4 x (0,5 - 4,0mm2) 20 A J803 Suitable for use in inac- Junction Box 4 x 4 x (0,5 - 4,0mm2) 20 A J804 cessible locations Traditional Junction Box 4 20 A J201 Acceptable for locations 4 20 A J301 which are accessible 3 30 A J401 6 20 A J601

6 hager solutions

Downlighter Solution 1 When fitting recessed downlighters the following method would overcome all the issues raised previously. It can be seen here that the sheath of both solid conductors and flexi- ble conductors for the light fitting can be secured as they enter the enclosure. This enables compliance with regulation 522.8.5 in particular where it states that there shall be no undue mechanical strain on the terminations of the conductors. Also regulation 526.5.3, which requires the cores of sheathed cables from which the sheath has been removed to be enclosed, can be seen to be complied with. Regulation 526.2 is complied with where the method of connection shall take account of the number and shape of wires forming the conductor. In this junction box solid conductors and flexible conductors can be terminated separately by means of the unique three plate style terminal arrangement.

Maintenance Free Solution 2 Maintenance free terminals provide one solution where accessibility is an issue. Tests, including long term vibration, shock test, long term connection test, pull out, voltage drop, temperature rise and exposure to corrosive atmospheres validate the suitability of these terminals. Equally suitable are solutions such as a ‘joint made by a compres- sion tool’. Maintenance free terminals have the additional advantages of allowing the direct insertion of solid, stranded or flexible conductors, and allowing the connection of up to four conductors from 0.5mm2 to 4.0mm2.

7 Location of consumer units

“A shall be located in a location where it is readily accessible. A wallmounting distribu- tion board shall be mounted at a height not exceeding 2.25m measured from the floor to the top surface of the board or 1.4m measured from the floor to the bottom of the board (530.5.3)”

This is illustrated on the picture above. The reason for the inclusion of this Regulation is again primarily an accessibility issue. It is firstly important for an end user to be able to readily see which devices have deactivated in the case of a fault, but due to the awkward nature of traditional locations for distribution boards, it may be dangerous for any persons to gain access by extreme means – climbing, stretching,etc. By making a distribution board more easily accessible general safety is increased and access to the distribution board is improved.

8 1. Location Concerns

Hager has anticipated inconveniences that may arise from this Regulation however, in that the lower distribution board may: • Interfere with the aesthetic appearance or design of a room • Cause obstruction through smaller or narrower areas where the board is installed • Cables may have to run down a wall from the ceiling in order to reach the consumer unit

2. Volta Flush Solution

A practical solution for installers who discover that the location of the distribution board under the new regulations will cause such inconvenience would be to use a flush mounting distri- bution board. Hager can provide various sizes of flush boards, with standard or special device configuration built in to suit most domestic or commercial applications. Domestic flush consumer units also have a wide variety of door finis- hes, which have the potential to contribute positively to a parti- cular design of a room.

3. Gamma Trunking Solution There may however be cases where using a surface moun- ted consumer unit is unavoidable. This may mean that cables will have to run down the wall to reach the top of the unit, which can appear untidy. A good solution is to use cable trunking, which will block any cables from view, while ensuring the cables are not dangerous.

Hager’s standard surface consumer unit uses the design award winning Gamma type enclosures.The stylish trunking for this can be seen in the pictures - full details available upon request.

9 Water Heating and Bathroom applications

The Regulation have expressed the need for extra RCD / RCBO protection when installing in certain situations. In this section it deals with requirements for installing water heating appliances, (such as a shower unit or immersion heater), and also for electrical equipment in rooms with baths and/or shower basins.

The diagram on the right shows the zoning set out for bathrooms. Regulation701.416.1 outlines the requirements for RCDs in bathrooms: “In all zones of a room containing a bath or a shower, every circuit shall be protected by an RCD having a rated residual operating current not exceeding 30mA, except circuits protected by Safety Extra Low Voltage (SELV)” All Hager RCDs can be found on pages 18 and 19.

10 Water Heating Appliances

It may be common practice in Ireland at the moment for installers to protect a shower circuit with a Residual Current Device (RCD). In Part 5, Chapter 55, Regulation 555.3.1 states that any circuit supplying a water heating appliance e.g. a shower unit or an immersion heater, shall be protected by an RCD having a rated residual operating current not exceeding 30mA. It is important to note that a separate RCD or RCBO shall be provided for each water heating appliance circuit.

Furthermore, Regulation 555.3.2 states that a circuit supplying auxiliary equipment associated with water services and water systems (e.g. pumps) shall be protected by an RCD having a rated residual operating current not exceeding 30mA. Examples of this may include pumps for rural group water schemes or agricultural irrigation systems.

Shown above is the SBE804, the Hager standard consumer Hager can supply this or any other configuration in a wide unit solution for water heating appliances applications. The variety of enclosures such as flush or IP65 applications. The 4th standard 2 row consumer unit has an extra 40A RCBO, 63A edition rules also apply to commercial installations, for which RCD and 2 MCBs, ensuring separate RCD protection for a shower Hager has a wide range of metal and polyester solutions. unit and immersion heater for example.

11 Protection of “meter tails”

The new 4th Edition Regulations take into account the fact that often the cables running from the ESB supply meter to the consumer unit in a premises are not protected with any device. The Regulations now state that all such cables, if longer than 3m, must be protected with no less than a 63A protective device.

12 Positioning In order to comply with 533.35 installers will have to ensure Hager provides the solution to this new requirement.The that the main current device, not less than 63A, must be located MCU63 (pictured opposite) is an IP65 enclosure, containing a in the standard ESB meter cabinet, in an enclosure rated at single pole 63A , which can be mounted neatly in least IP55 and constructed of a non-conducting material. the bottom right of the ESB Cabinet, ensuring sufficient pro- The location of this enclosure must be in the bottom right corner tection for the cables running through the installation to the of the meter box (as shown on the left) to allow for fitting of distribution board. subsequent additional equipment.

“430.3 position of main device A main current protective device shall be provided in every installation as follows At the main supply point in 1 accordance with 533.3.5; or

Within 3m of the supply point pro- vided the conductors upstream of the device:- - are installed in such a manner as to reduce the risk of a short circuit 2 to a minimum e.g. by suitable protection, and - are installed in such a manner as to reduce to a minimum the risk of fire or danger to persons e.g. by ensuring they are not placed near combustible material, and - have no branch connections ”

13 Surge Protection

Part 4 covers the area of surge protection. Different types of companies rely on a constant supply of electricity in order to keep machines or equipment running. Even slight or brief surges of electricity in circuits can often lead to machinery or equipment being damaged, which can have adverse effects, for business owners or end users. Such installations, which depend greatly on the smooth running of equipment, are recommended to have extra protection for electrical surges, which will minimise damage to equipment or machinery.

The installer in relation to the following must evaluate the need These devices are strongly recommended in the 4th Edition for protection against over-voltage in an installation: Wiring Regulations on installations that are exposed to these • Consequence for human life e.g. safety services, medical transients in order to protect equipment such as PCs, alarms, equipment in hospitals etc. TVs and a wide range of commercial and industrial machines. • Loss of services in places of public resort e.g. IT centres, The choice of SPD depends on a number of criteria such as: museums, art galleries etc. • The exposure of the installation to transients • Consequences for industrial, commercial or agricultural • The sensitivity, value and social importance of the equipment activity and equipment. that requires protection • Hager’s wide range of Surge Protection Devices (SPDs) protect • Level of protection sensitive and often expensive equipment against transients, originating from lightning, switching of motors, and lighting.

14 Device Selection 1. Curve Types

Regulation 533.3.4 states that MCBs and RCBOs shall have type B overcurrent characteristics except in the following cases: • On circuits where high inrush currents of the order of 5 – 10In may occur (e.g. motors) –in this case Type C devices will be used • On circuits where very high inrush currents of the order of 10 - 20In may occur (e.g. transformers) – in this case Type D devices will be used

I d ~ 2. DC Sensitivity Type AC Residual Current Devices (RCDs) and Residual Current Breaker with Overcurrent Protection (RCBOs) must be chosen according to application. The time to choose something other than an A.C. type device is when the possibility exists of the presence t of D.C. components in a circuit. 531.2.1.3 of the 4th Edition Regulations states “Account shall be taken of the possible presence of D.C. com- I d ~ ponents in a circuit protected by an RCD that could affect the operation of the RCD, and a suitable type should be chosen. Type A

t ~ Id or

Type B

t 3. Making the right choice For all new installations the right type of protection device must be chosen according to the 4th Edition Regulations on curve types and sensitivity as described above. Hager’s range of protection devices makes it easy for the installer to choose the right equipment for the installation, ensuring excellent quality and compliance with the Regulations. See our full listing on pages 18 and 19.

15 Special Installations

The 4th Edition Regulations have also provided for extra measures ensuring safety on special installations or locations.

Depending on the type of installation, Part 7 of the Regulations sets out to ensure that circuits have the necessary RCD sensitivity and in turn that the devices are housed in the correct enclosure type. Hager provides the solutions to the new requirements for special installations with its wide range of RCDs and RCBOs (see overleaf) and Orion Plus polyester Enclosures, available in a suitable variety of sizes. While it is up to the installer to decide what equipment will be used for each situation, Hager is always happy to help with selection of the right product. Browse our Website for more information or call our Technical Helpline on 1890 551 502

16 Special Installations or locations

704 - Construction & Demolition Site Installations Regulation 711.411.3.02 Regulation 704.410.01 & 704.410.02 • Additional protection required for all final circuits rated up to • Final circuits feeding sockets up to 32A - RCD IDn ≤ 30mA 32A by 30mA RCD. • Circuits feeding socket outlets rated over 32A should have RCD IDn ≤ 500mA 740 – Fairgrounds amusement parks and circuses Regulation 704.530.5.04 Regulation 740.411.3.01 • Enclosures containing the supply authority’s equipment shall • Automatic disconnection of the supply to the temporary be made of non-conductive material and shall have a degree structures shall be provided at the origin of the installation by protection of IP55 RCDs with a rated residual operating current not exceeding 300mA. Such RCDs shall incorporate a time-delay or be of 705 –Agricultural & Horticultural premises the S type, sensure discrimination with RCDs protecting final Regulation 705.41.3.01 – automatic disconnection of supply circuits, and shall comply with 531.2. • Final circuits feeding sockets up to 32A - RCD IDn ≤ 30mA Regulation 740.416.1.01 • Circuits feeding socket outlets rated over 32A - RCD IDn ≤ 100mA • Final circuits for lighting, socket-outlets rated up to, and • All other circuits - RCD IDn ≤ 300mA including, 32A and portable equipment connected by means Regulation 705.56 Safety Services of a flexible cable or cord with a current-carring capacity not • Backup supplies considered if necessary for life support of exceeding 32A shall be provided with additional protection livestock by an RCD having a rated residual operating current not exceeding 30mA 711 - Exhibitions, Shows and Stands Regulation 740.530.5.02 Regulation 711.411.3.01 • 740.530.5.02 Switchgear enclosures containing the DSO • Cables supplying temporary structures protected by RCD equipment shall be made of non-conductive material and rated up tp 300mA (S type for time discrimination with down- shall have a minimum degree of protection IP55 stream RCD)

17 RCD Suggested Application Chart

Type AC sensitive

Suggested application Current Rating Sensitivity 2 Pole 4 Pole Standard domestic and commercial 16 A 10mA CCC216U Standard domestic and commercial 25 A 30mA CDC225W CDC425W Standard domestic and commercial 40 A 30mA CDC240W CDC440W Standard domestic and commercial 63 A 30mA CDC263W CDC463W Standard domestic and commercial 80 A 30mA CDC280W CDC480W CDC440W Standard domestic and commercial 100A 30mA CDC284W CDC484W Agricultural & Horticultural 25 A 100mA CEC225W CEC425W Agricultural & Horticultural 40 A 100mA CEC240W CEC440W Agricultural & Horticultural 63 A 100mA CEC263W CEC463W Agricultural & Horticultural 80 A 100mA CEC280W CEC480W Agricultural & Horticultural 100 A 100mA CEC284W CEC484W Agricultural & Horticultural, Exhibitions, Shows, 25 A 300mA CFC225W CFC425W Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 40 A 300mA CFC240W CFC440W Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 63 A 300mA CFC263W CFC463W Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 80 A 300mA CFC280W CFC480W Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 100 A 300mA CFC284W CFC484W Stads, Fairgrounds, Amusement parks, Circuses

Time delayed Type S

Suggested application Current Rating Sensitivity 2 Pole 4 Pole Exhibitions, Shows, Stads, Fairgrounds, 100 A 100mA CN284W CN484W Amusement parks, Circuses Exhibitions, Shows, Stads, Fairgrounds, 100 A 300mA CP284U CN484U Amusement parks, Circuses

CN284W

Type A DC sensitive

Suggested application Current Rating Sensitivity 2 Pole 4 Pole Equipment producing pulsating DC currents 16 A 10mA CCA216U Equipment producing pulsating DC currents 25 A 30mA CCA225U CDA425U Equipment producing pulsating DC currents 40 A 30mA CCA240U CDA440U Equipment producing pulsating DC currents 63A 30mA CCA263U CDA463U CGC225F CGC425F CGC440F Construction & Demolition sites 25 A 500mA Construction & Demolition sites 40 A 500mA CGC240F CGC440F Construction & Demolition sites 63 A 500mA CGC263F CGC463F

Type B DC sensitive

Suggested application Current Rating Sensitivity 2 Pole 4 Pole Equipment producing smooth DC currents 40 A 30mA CDB440F Equipment producing smooth DC currents 63 A 30mA CDB463F Equipment producing smooth DC currents 40 A 300mA CDB440F Equipment producing smooth DC currents 63 A 300mA CDB463F

CDB440F

18 RCBO Suggested Application Chart

Type AC sensitive

Suggested application Current Rating Sensitivity Curve type B Curve type C Standard domestic and commercial 6 A 30mA ADC856W ADC806W Standard domestic and commercial 10 A 30mA ADC860W ADC810W Standard domestic and commercial 16 A 30mA ADC866W ADC816W Standard domestic and commercial 20 A 30mA ADC870W ADC820W Standard domestic and commercial 25 A 30mA ADC875W ADC825W ADC870W Standard domestic and commercial 32 A 30mA ADC882W ADC832W Standard domestic and commercial 40 A 30mA ADC890W ADC840W Agricultural & Horticultural, Exhibitions, Shows, 6 A 300mA AF956B Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 10 A 300mA AF960B Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 16 A 300mA AF966B Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 20 A 300mA AF970B Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 25 A 300mA AF975B Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 32 A 300mA AF982B Stads, Fairgrounds, Amusement parks, Circuses Agricultural & Horticultural, Exhibitions, Shows, 40 A 300mA AF990B Stads, Fairgrounds, Amusement parks, Circuses

Type A DC sensitive

Suggested application Current Rating Sensitivity Curve type B Curve type C Equipment producing pulsating DC currents 6 A 30mA ADA506D ADA556D Equipment producing pulsating DC currents 10 A 30mA ADA510D ADA560D Equipment producing pulsating DC currents 16 A 30mA ADA516D ADA566D Equipment producing pulsating DC currents 20 A 30mA ADA520D ADA570D Equipment producing pulsating DC currents 25 A 30mA ADA525D ADA575D ADA916D Equipment producing pulsating DC currents 32A 30mA ADA532D ADA582D Equipment producing pulsating DC currents 40 A 30mA AD940J AD990J Equipment producing pulsating DC currents 6 A 300mA AF956J Equipment producing pulsating DC currents 10 A 300mA AF960J Equipment producing pulsating DC currents 16 A 300mA AF966J Equipment producing pulsating DC currents 20 A 300mA AF970J Equipment producing pulsating DC currents 25 A 300mA AF975J Equipment producing pulsating DC currents 32 A 300mA AF982J Equipment producing pulsating DC currents 40 A 300mA AF990J

19 Hager (Ireland) Ltd. Tel: +353 (0) 1 - 883 5844 Unit M2 Furry Park Industrial www.hager.ie Estate Old Airport Road Dublin 9

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